Boring Cylinder

WARNING: This page is about a different car, the 2005 Dodge Stratus and 2005 Chrysler Sebring. However, it is still accessible from the selected car via links, so may be relevant.

Oversize pistons to be used should be determined on the basis of the largest bore cylinder.

Fig 1: Measuring Boring Cylinder

Courtesy of DAIMLERCHRYSLER CORPORATION

Piston size identification

PISTON SIZE IDENTIFICATION

SIZE	IDENTIFICATION MARK
0.50 mm (0.020 in) oversize diameter	50
1.00 mm (0.040 in) oversize diameter	100

NOTE: Size mark is stamped on the piston top.

Measure the outside diameter (OD) of the piston to be used. Measure it in thrust direction as shown.
Based on the measured piston OD, calculate the boring finish dimension.
Boring finish dimension = Piston OD + (clearance between piston OD and cylinder) - 0.02 mm (0.0008 inch) (honing margin)

CAUTION: To prevent distortion that may result from temperature rise during honing, bore cylinders, working from number 2 to number 4 to number 1 to number 3.
Bore all cylinders to the calculated boring finish dimension.
Hone to the final finish dimension (piston OD + clearance between piston OD and cylinder).
Check the clearance between the piston and cylinder.
Clearance between piston and cylinder: 0.02 - 0.04 mm (0.0008 - 0.0015 inch)

NOTE: When boring cylinders, finish all of four cylinders to the same oversize. Do not bore only one cylinder to an oversize.